Wall system and method with integral channel

ABSTRACT

An insulating concrete form wall system includes integral channels for routing wiring, cables and other lines. The channels are formed into the insulating layers of the walls and form part of the insulating layer. The channel members include a bottom portion having an interlocking device configured for interlocking with the poured concrete. The channel members have opposed side portions extending from edges of the bottom portion to define an open channel. Insulation engagement devices extend from the sides to engage the insulating concrete form elements.

BACKGROUND OF THE INVENTION

The present invention relates to a wall system employing insulating concrete form construction having an integral channel formed therein and to a method of making such an insulating concrete form wall with an embedded channel.

FIELD OF THE INVENTION

Insulating concrete forms are used for walls of concrete construction. The insulating forms provide a cavity into which the concrete is poured while the forms themselves remain in place in the finished wall and provide superior insulating qualities over conventional wood frame construction. The resulting wall provides improved strength as well as having built in insulation layers. Such construction techniques provide solid, long lasting construction that resists fire, wind, termites and other common elements that plague wood frame construction. Moreover, insulating concrete forms have advantages over conventional concrete block construction by providing two built in layers of insulation over a thick center poured concrete portion. The resulting structures have greater energy efficiency, are quieter and stronger. Such systems also have lower maintenance.

Concrete walls are typically reinforced with rebar or other members embedded and interconnected in the concrete. The insulated concrete forms typically are polystyrene forms that are configured to remain in place during concrete pouring and define spaces for receiving poured concrete. These blocks are configured for stacking and remaining as a portion of the finished wall. In other configurations, insulating panel type forms are used on each face with ties extending between opposite insulating layers. The blocks and panels may have tongue-in-groove edges or other engagement structures that provide alignment and engagement between the insulating elements.

Although insulating concrete forms have many advantages and benefits, a common difficulty arises from placing wiring, plumbing, cables, central vacuum ducts and other lines through the walls. It is usually necessary to fish the lines through an orifice formed through the insulating form layer. Moreover, this technique is somewhat unsightly and problems are compounded when lines must be placed after sheetrock or other common wall materials have been placed over the insulating concrete form wall.

It can be seen then that a new and improved insulating concrete form system is needed that provides space integrated into the wall for running various types of lines, cables and/or ductwork. Such a system should achieve all the benefits of insulating concrete form wall systems and provide for easy construction at low cost while providing improved access over prior construction techniques. The present invention addresses these as well as other problems associated with channeling for insulating concrete form systems.

SUMMARY OF THE INVENTION

The present invention is directed to an insulating concrete form (ICF) system and method of constructing an insulating concrete form wall. The system includes conventional insulating forms that form inner and outer insulating layers. The system also utilizes conventional ties for building block types forms to define a cavity for receiving poured concrete. Channel elements are configured for inserting into the insulating concrete form layer during initial construction and forming an integral part of the insulating layers in the wall system when finished.

The channel element includes sides and a bottom with a T-slot formed at the bottom. Alignment tabs and ribs extend from an outer face of the sides to engage the foam insulation elements. The channel element inserts into the insulating concrete form system during construction as a portion of the insulating layer and remains in place.

To construct the system, the insulating forms are built in an interlocking stacked configuration as in a conventional (ICF) construction method with blocks or panels until a level is reached where it is desired to insert a channel. A channel member (or members) is then placed on the top of the current uppermost insulating layer with the engagement ribs and alignment tab positioning and engaging the foam insulation. The wall continues to be built with blocks or panels above the channel with the insulating forms engaging the ribs at the top of the channel elements and aligned by the upward extending alignment tab. The ties insert into and engage the T-slot and are used in a conventional manner to connect the insulating layers. When the insulating layers have been constructed, to form a center cavity for poured concrete, rebar is inserted and the concrete is poured into the cavity formed between the insulating layers using conventional insulating concrete form construction techniques. Outlets and vacuum access points are inserted into the insulating layers. The concrete flows into and engages the T-slot on the bottom of the channel member and provides greater connection and improved strength. Inner and outer faces are finishing using conventional techniques and material.

These features of novelty and various other advantages that characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and the objects obtained by its use, reference should be made to the drawings that form a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an insulating concrete form system according to the principles of the present invention;

FIG. 2 is an end elevational view of a first embodiment of a channel member installed in the system shown in FIG. 1;

FIG. 3 is a perspective view of the channel member shown in FIG. 2;

FIG. 4 is a top plan view of the channel member shown in FIG. 2;

FIG. 5 is a diagrammatic view showing an installation method for the system shown in FIG. 2;

FIG. 6 is a perspective view of an insulating concrete form having opposed walls known from the prior art; and

FIG. 7 is an end elevational view of a second embodiment of a channel element for the system shown in FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the drawings and in particular to FIG. 1, there is shown an insulating concrete form (ICF) system 22 forming an insulated concrete wall 20. The insulating concrete form system 22 includes planar panel-type forms 24 in a first embodiment. The forms 24 are planar block-type elements and are typically made of a form insulation such as expanded polystyrene. The forms 24 are generally configured to be stacked in an edge to edge relationship to form a continuous planar insulating wall portion. The system 22 generally include an inner insulating layer 50 and an outer insulating layer 52. The edges may include complementary tongues, grooves or other structures configured to facilitate attachment and alignment. In addition, ties 28 may extend between at least some forms 24 of the inner insulating layer 50 and the outer insulating layer 52 to provide support during pouring of the concrete, as explained hereinafter.

Intermediate the inner insulating layer 50 and outer insulating layer 52 is a center concrete core layer 26. The concrete 26 generally fills the cavity formed between the inner insulating 50 and outer insulating layer 52. Rebar 29 or other conventional reinforcement members may extend within the concrete layer to provide added strength and support. The inner insulating layer 50 and outer insulating layer 52 are left in place to provide a mounting surface for finishing and attachment of an additional finishing layer such as stucco, paneling stucco, brick or siding on the outer insulating layer 52 and wall board, drywall, paneling or other finishing layers on the inner insulating layer 50.

In addition, at least one channel 30 extends in the insulting layers 50 and/or 52. The channel 30 provides for placement of wiring, plumbing, duct work, cables and other lines with easy access to the open top portion of the channel 30 that faces to the outer faces of the wall system 20. The channel 30 is generally horizontal, but may also include one or more intersecting vertical channel branches and lead to outlets and other line ends or access points 130. Moreover, other horizontal channels 30 may be added as needed in the inner insulating layer and outer insulating layer to accommodate the various lines that are to be installed. The channel element 30 may be made of an extruded plastic material providing light weight and sufficient strength and rigidity at a low cost. The channel element 30 may also be a styrene channel or may be metal, such as cold rolled steel or aluminum that provides suitable strength and is lightweight.

Referring now to FIGS. 3-5 and 7, the channel member 30 includes a bottom portion 32 and opposed sides 34. A T-slot 36 is formed in the outer surface of the bottom portion 32. The T-slot is configured so that when the concrete is poured into the space defined by the forms 24, the concrete flows into the T-slot and forms a mechanical lock with the channel 30 after the poured concrete 26 sets. Each side 34 also includes an alignment tab 38 extending laterally outward from the side 34 as shown in FIG. 4 and engaging an inner surface of an insulating form 24 to provide proper placement and alignment between the channel 30 and the form 24. Ribs or teeth 40 extend slightly from the sides 34 and are configured for extending into the edge of the adjacent forms 24. In the embodiments shown in FIGS. 2 and 7, the bottom portion 32 is a double wall construction for greater strength and to create a reinforced interlock connection portion that may receive a metal bar, such as may aid in providing increased structural integrity as may be needed at corners or other critical locations. A bottom T-shaped flange 42 extends up from the bottom. Flanges 44 extend inward from the sides of the channel and provide guides for inner bracing, if needed. Moreover, retainers 46 also extend inward from the channel 30 and provide additional support and mounting for inner bracing and/or engagement and arrangement of wiring and other elements to maintain proper position within the channel 30. It can be appreciated that with the present insulating concrete form system 22, the channel member 30 forms a portion of the insulating layer 50 and/or 52 to provide a cleaner appearance while being inserted during conventional construction of the wall 20.

Referring now to FIG. 6, there is shown a second embodiment of a known insulating concrete form 124. The block-type forms 124 includes opposed wall portions 126 connected by cross-bracing 128. The block-type forms 124 do not require ties and can be constructed by building tiers in a simple stacking configuration in a manner similar to the construction of the walls including forms 24. It can be appreciated that the block-type forms 124 create a continuous cavity in the wall into which the concrete may be poured with braces extending bottom block-type forms 124. In tiers in which the channel 30 is inserted, a planar member or other insert is placed on the opposite side or channels 30 are placed on both the inner and outer sides of wall. It can be appreciated that the blocks 124 may take on many other configurations well known in the art and that the channels may also be easily utilized with other configurations of the insulating blocks 124.

Referring now to FIG. 5, construction using the channels 30 of the present system for insulating concrete form walls requires no special building techniques or tools as compared to construction without channels 30. At least a first tier or row of forms 24 are placed at the construction site. Additional levels of blocks may also be added and built upward in a stacked configuration using conventional techniques. Where a channel 30 is to be placed, the channel member is placed on top of the then completed layer 50 or 52 and a channel 30 or planar form 24 is placed on the opposite wall. Construction continues with ties 26 being placed and connecting between the layers 50 and 52 in a conventional manner. The insulating blocks 24 are placed on top of and in engagement with the sides 34 of the channel aligned by the tabs 38 and engaging the ribs 40. The wall is then built above the channels 30 in a conventional manner until the desired height is achieved. In addition, vertical channels 130 are placed into the layer 50 or 52 and held in place by the tabs and ribs. The T-slot 36 also provides for engagement by ties 28 to provide further positioning and added strength and connection between the opposite insulating layers 50 and 52. When the layers 50 and 52 have been completed, rebar or other reinforcements are placed into the wall cavity and the concrete is then poured in the cavity formed between the layers. The concrete flows between the cavities and into the T-slot 36 to provide added strength and connection to the channels 30. The wall 22 is then allowed time for the concrete to set in conventional manner.

The resulting insulating concrete form system wall 20 includes integral channels 30 that may receive the various lines, ducts, plumbing, etc. and is ready for the receiving finishing layers. The use of channels 30 avoids having to fish wiring and other lines through the wall and provides a clean finish and easy access. Should lines need to be replaced or added after initial construction, pulling and feeding new lines is easily accomplished through the channels 30.

Although the channels 30 may be cut to length and may come in several sizes, the channel generally comes in common standard lengths, such as 48 inches and may have a common width in sizes complementary to conventional concrete forms 24. Channels are typically made of common plastic extruded material such as PVC and have width dimension of 3½ inches deep by 4⅛ inches wide with ⅝ inch or ¾ inch flanges. It can be understood that the size is sufficient to accommodate a standard electrical outlet box or large diameter plumbing pipes in certain embodiments. The system is also installed during the normal construction and requires no special tools or installation skills, requiring only techniques and tools such as may be needed with conventional systems.

In a second construction method, the inner and outer layers are constructed in panels with integral channels 30 and the entire layers 50 and 52 are then erected and tied together with the ties 28. The concrete is then poured in a conventional manner to form the wall 20 as described above.

The present insulating concrete form system and method is adapted for use with standard building systems and installing electrical and service lines with a professional appearance. The present system is inexpensive and provides for using standard electrical, plumbing and other building components and easy remodeling or upgrades with low impact. The system allows use of lower grade paid labor and eliminates much of the expensive labor in code related technical work. The present system and method also affords significant reduction and reconstruction layout and assembly costs. Moreover, the system is compliant with known building codes and specification.

It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. 

1. An insulating concrete form wall channel member, the wall having a plurality of insulating concrete form elements to make an extended vertical insulating concrete form, the channel member comprising: a bottom portion having an interlocking device configured for interlocking with concrete; opposed side portions extending from edges of the bottom portion, the side portions and bottom portion defining an open channel, each side portion having an insulation engagement device configured for engaging the insulating concrete form elements.
 2. A channel member according to claim 1, wherein the member is an extruded member.
 3. A channel member according to claim 1, wherein the member is plastic.
 4. A channel member according to claim 1, wherein the member is vinyl.
 5. A channel member according to claim 1, wherein the member comprises a monolithic extruded vinyl member.
 6. A channel member according to claim 1, wherein the member is styrene.
 7. A channel member according to claim 1, wherein the member comprises a cold rolled steel member.
 8. A channel member according to claim 1, wherein the member is aluminum.
 9. A channel member according to claim 1, wherein the channel member comprises a lateral engagement device on each side.
 10. A channel member according to claim 1, wherein the channel member comprises a concrete engagement device extending from the bottom.
 11. A channel member according to claim 1, wherein the channel member comprises a concrete engagement device extending from the bottom.
 12. A channel member according to claim 1, wherein the channel member comprises a T-slot formed in the bottom.
 13. A channel member according to claim 1, wherein the channel member comprises a barb extending laterally from each side.
 14. An insulating concrete form system, comprising: a plurality of insulating elements configured for edge to edge engagement to form an extended vertical planar insulating layer and having a front finishing face and a rear concrete engaging face, wherein the rear face is configured for retaining concrete; a channel element having opposed sides connected by a bottom defining a channel opening to the front finishing face, the channel element inserting into the wall, wherein the sides engage adjacent insulating wall elements.
 15. An insulating concrete form system according to claim 14, wherein the channel element extends horizontally and engages adjacent insulating elements.
 16. An insulating concrete form system according to claim 14, wherein the channel element comprises a lateral engagement device on each side mechanically engaging the adjacent insulating elements.
 17. An insulating concrete form system according to claim 14, wherein the channel element comprises a concrete engagement device extending from the bottom and mechanically engaging the concrete.
 18. An insulating concrete form system according to claim 14, wherein the channel element comprises a concrete engagement device extending from the bottom.
 19. An insulating concrete form system according to claim 14, wherein the channel element comprises a barb extending laterally from each side.
 20. An insulating concrete form system according to claim 14, wherein the system comprises intersecting channel elements.
 21. An insulating concrete form system according to claim 14, wherein the channel element comprises a T-slot formed in the bottom.
 22. An insulating concrete form system according to claim 14, wherein the insulating elements comprise blocks have a cavity formed therein for receiving concrete.
 23. A method for making an insulating concrete form wall, comprising: creating a first tier of insulating concrete forms; placing a horizontal channel element on the first row of insulating concrete forms and engaging the top of the first row of insulating concrete forms; placing a second tier of insulating concrete forms on the horizontal channel element and engaging the top of the horizontal channel element.
 24. A method according to claim 23, further comprising placing at least a third tier of insulating concrete forms on the second tier of insulating concrete forms to form a first continuous vertical wall.
 25. A method according to claim 23, further comprising creating one or more additional tiers of insulating concrete forms below the first tier prior to creating the first tier.
 26. A method according to claim 24, further comprising creating a second continuous vertical wall spaced apart from the first continuous vertical wall and tying the first continuous vertical wall to the second continuous vertical wall.
 27. A method according to claim 23, wherein the insulating concrete forms comprise block elements having spaced apart walls defining a concrete receiving space and portions connecting the spaced apart walls.
 28. A method according to claim 23, wherein the first tier, the channel and the second tier are connected in an assembly at a remote location and wherein the assembly is installed at the worksite. 